Methods of Constructing Buildings using steel containers

ABSTRACT

A building is provided, comprising at least two shipping containers, said containers comprising a top wall, a bottom wall, and two opposed side walls, said containers being mounted to a foundation in a spaced-apart, parallel manner, wherein portions of the adjacent inner side walls of said containers are removed, and further wherein a roof is attached to the top walls of said containers.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplication Ser. No. 61/503,045, with a filing date of Jul. 27, 2011,which is expressly incorporated herein in its entirety by referencehereto.

FIELD OF THE INVENTION

The present invention relates generally to methods of constructingbuildings for commercial and residential use, and in a particular thoughnon-limiting embodiment, to a method of constructing buildings using acombination of standard construction materials and steel containers.

BACKGROUND OF THE INVENTION

There are many known methods in the art for constructing a building.Typically a building is constructed on-site, requiring many hours ofskilled labor and using common construction supplies, such as brick,mortar, and lumber. Such supplies are often very costly. Furthermore,typical construction may not be strong or durable enough in certainareas of the country more prone to earthquakes, hurricanes, and otherserious weather.

Recently, more cost-effective methods of construction have beenproposed. One such method is to fabricate a building of steel in afactory and then move the building to the desired site. This method hasproven to be faster and less expensive than traditional constructionmethods.

However, the metal used in such construction is very heavy and expensiveto transport. Also, when using a traditional pre-fabricated metalbuilding, there is a subsequent inability to expand the interior userspace. Furthermore, steel buildings are frequently not as aestheticallypleasing, and do not have the look or feel of a traditionallyconstructed building. There is, therefore, a long-standing yet unmetneed for methods of constructing homes in a stronger, economical andtime-efficient manner, while still pleasing prospective ownersaesthetically.

Turning for a moment to a seemingly unrelated issue, as more productsare shipped to the U.S. from overseas, particularly Asia, ever greaternumbers of metal shipping containers have begun stacking up in the majorshipping ports. Consequently, it is oftentimes less expensive to buy newshipping containers in Asia than it is to ship the old containers backto the U.S. Moreover, the useful life of a standard shipping containeris only about five (5) years. After that time, the containers just sitempty in abandoned shipyards.

A standard shipping container range from 19 feet to 55 feet long, 7 feetto 9 feet wide and 8 feet to 10 feet high. The containers are typicallymade of stronger steel than standard steel, known as Cor-ten steel,which does not rust or corrode. Furthermore, the steel ismold-resistant. The floor of a standard shipping container is made ofhardwood and is constructed to withstand several tons of internalweight. The containers are built to withstand typhoons, tornadoes,hurricanes, and earthquakes.

Due to their durability, adaptability, light weight, low cost, and easeof stackability, new ideas for reusing the containers are currentlybeing sought.

The shipping containers have been used in the past as storage units,temporary secure spaces at construction sites, and make-shift shelters.Furthermore, the containers have been used as small offices, workshops,or even employee quarters.

Therefore, there is also a long-standing yet unmet need to designmethods of using the shipping containers in new and novel ways.

SUMMARY OF THE INVENTION

A building is provided, including at least two shipping containers, saidcontainers comprising a top wall, a bottom wall, and two opposed sidewalls, said containers being mounted to a foundation in a spaced-apart,parallel manner, wherein portions of the adjacent inner side walls ofsaid containers are removed, and further wherein a roof is attached tothe top walls of said containers.

BRIEF DESCRIPTION OF THE DRAWINGS

For a further understanding of the nature, objects, and advantages ofthe present invention, reference should be had to the following detaileddescription, read in conjunction with the following drawings, whereinlike reference numerals denote like elements and wherein:

FIG. 1 is a schematic diagram showing side (1A) and top views (1B and1C) of a 10-story embodiment.

FIG. 2 is a schematic diagram showing a side view of a configurationaccording to an example embodiment, with the recessed-in option oneither one side or both.

FIG. 3 is a schematic diagram showing a side view of a configurationaccording to an example embodiment, with the recessed-in option oneither one side or both.

FIG. 4 is a schematic diagram showing a side view of a configurationaccording to an example embodiment, with the recessed-out option oneither one side or both.

FIG. 5 is a schematic diagram showing a side view of a configurationaccording to an example embodiment, with the recessed-out option oneither one side or both.

FIG. 6 is a schematic diagram showing a side view of a configurationaccording to an example embodiment, raised with additional containersand the option of vertical containers.

FIG. 7 is a schematic diagram showing a side view of a configurationaccording to an example embodiment, with stacked and/or detachedcontainers including an example roof configuration.

FIG. 8 is a schematic diagram showing a top view of a configurationaccording to an example embodiment, including attached or detached unitgroups.

FIG. 9 illustrates the support detail according to example embodiments.

DETAILED DESCRIPTION

In an example embodiment of the present invention, metal shippingcontainers or other suitable metal containers are used in combinationwith traditional construction methods and materials in order to producea hybrid-construction building. In example embodiments, the shippingcontainer(s) serve as strong structural elements of the building. Unlikemore traditional, all-metal pre-fabricated buildings,hybrid-construction buildings look and feel more like traditionalbuildings, yet still have the advantages of a pre-fabricated metalbuilding, including faster construction, simplified labor, and reducedconstruction costs.

The cost of purchasing the shipping containers is less than that oftraditional construction materials, such as bricks and mortar.Furthermore, using the containers as the structural element of abuilding requires a smaller and less expensive foundation thantraditional materials.

In exemplary embodiments, the shipping containers are used as modularelements that can be combined and connected in a manner to form larger,stronger structural frames for a building.

The variety of examples embodied in FIGS. 1-9 is provided to illustratea sample of arrangements. The examples of arrangements andconfigurations are not intended to limit the possibilities of interioror exterior configuration of containers or the use of interior spaces.

FIGS. 1-9 illustrate example embodiments of structures for residentialuse or light commercial spaces. According to example embodiments, thestructures range from one to ten stories high, stacked either at aparallel or perpendicular to each other. Further examples are stacked ata 90 degree angle flush at the corners to form a square or rectangleconfiguration, with the option to move one side or both sides in or out,up to eight feet depending on the interior or exterior space desired.

Referring now to FIG. 1, an example embodiment of a building 30 isprovided. Containers 20 are set parallel to each other on raised supportcubes or reinforced concrete slabs. Containers 10 are likewise parallelto each other and stacked on top of containers 20, so that containers 20and containers 10 are perpendicular to each other. The corners ofcontainers 10 and corners of containers 20 are flush with each other.Next, another set of containers 20 are stacked on top of containers 10in the same manner, and so on and so forth. As shown in FIG. 1A, exampleembodiments are 10 stories high.

As shown in FIG. 1B, containers 10 and containers 20 are the same size,thereby forming a square configuration. In a further example embodiment,containers 10 and containers 20 are different sizes, forming a rectangleconfiguration, as shown in FIG. 1C.

Turning to FIGS. 2 & 3, a further example embodiment of a building 30 isprovided. In FIG. 2, the corners of containers 20 are, for some stories,flush with the corners of containers 10, but depending on the need ordesire for more or less space, the containers 20 and 10 are stacked in amanner such that the corners of containers 20 are recessed-in on eitherone side or both, up to 8 feet (see, e.g., stories 3, 5, and 6).

Turning to FIGS. 3, 4 & 5, a further example embodiment of a building 30is provided. In this embodiment, the containers 20 are stacked on top ofcontainers 10 so that additional space between containers 20 isprovided. The corners of containers 20 and 10 are stacked in a manner onsome stories such that the corners of containers 20 are recessed-out oneither on one side or both, up to 8 feet (see, e.g., stories 1, 3, 7,and 9).

Turning now to FIG. 6, additional containers 20 are provided at thebottom of the building 30, stacked vertically, to gain open space orheight below the building 30.

Turning next to FIG. 7, various roof 40 options are illustrated onvarious stacked and/or detached containers.

Turning now to FIG. 8, an example embodiment for a multi-family dwellingand/or a light commercial complex is provided. Multiple buildings 30 maybe joined with additional containers 50.

The containers are mounted to a foundation in a spaced-apart, parallelmanner, thereby forming the sides of one floor of the structure. Inbetween the containers, the space is enclosed to form the rest of theinterior space, using construction methods already known to those ofskill in the art. Access between the containers and the enclosed spaceis provided via doors or other means cut into the containers.

The containers provide actual additional usable space. In order tofurther increase the usable space of the building, the steel containersneed only be spaced further apart or closer together depending ordesired space. A common roof is installed over the containers and theenclosed space. In further exemplary embodiments, doors and windows maybe cut into either (or both) the steel containers or the enclosed space.

According to example embodiments, the structures range from one to tenstories high, stacked at a parallel and/or perpendicular and/or 90degree angle flush at the corners to form a square and/or rectangleconfiguration with the option to move one side or both sides in or outup to eight feet depending on the interior or exterior space desired.

FIG. 9 illustrates example embodiments of support cubes and concreteslabs. The steel containers may be mounted on a raised platforms(support cubes), thereby rendering the completed structure ideal forwater front construction. Typical concrete foundations will be installedto meet local code and have recessed areas for the container in anattempt to line-up the floor elevations, if desired.

In still further embodiments, the metal shipping containers withadditional anchoring could serve as an emergency shelter in case of aserious storm or other inclement weather, such as earthquakes,tornadoes, and the like.

The foregoing specification is provided only for illustrative purposes,and is not intended to describe all possible aspects of the presentinvention. While the invention has herein been shown and described indetail with respect to several exemplary embodiments, those of ordinaryskill in the art will appreciate that minor changes to the description,and various other modifications, omissions and additions may also bemade without departing from the spirit or scope thereof.

1. A building, comprising: at least two shipping containers, saidcontainers comprising a top wall, a bottom wall, and two opposed sidewalls, said containers being mounted to a foundation in a spaced-apart,parallel manner, wherein portions of the adjacent inner side walls ofsaid containers are removed, and further wherein a roof is attached tothe top walls of said containers.
 2. The building of claim 1, whereinsubstantially all of the adjacent inner side walls are removed.
 3. Thebuilding of claim 1, wherein the foundation is reinforced concreteslabs.
 4. The building of claim 1, wherein the foundation is a raisedplatform.
 5. The building of claim 1, further comprising at least oneadditional container, said additional container being stackedperpendicularly on the top walls of the at least two shippingcontainers.
 6. The building of claim 1, further comprising at least onadditional container, said additional container being stacked parallelon the top wall of one of the shipping containers.
 7. A method ofconstructing a building, comprising: providing at least two shippingcontainers, said containers comprising a top wall, a bottom wall, andtwo opposed side walls, mounting said at least two containers to afoundation in a spaced-apart, parallel manner, removing portions of theadjacent inner side walls of said containers, and attaching a roof tothe top walls of said containers.
 8. The method of claim 7, whereinsubstantially all of the adjacent inner side walls are removed.
 9. Themethod of claim 7, further comprising the step of stacking at least oneadditional container, perpendicularly on the top walls of the at leasttwo shipping containers.
 10. The method of claim 7, further comprisingthe step of stacking at least one additional container parallel to thetop wall of one of the shipping containers.